Page 1

PS–8

POWER STEERING – VANE PUMP

REMOVAL 1.

REMOVE FRONT WIPER ARM LH (See page WW-7)

2.

REMOVE FRONT WIPER ARM RH (See page WW-7)

3.

REMOVE HOOD TO COWL TOP SEAL (See page WW-7)

4.

REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-7)

5.

REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-7)

6.

REMOVE WINDSHIELD WIPER LINK ASSEMBLY (See page WW-8)

7.

REMOVE COWL PANEL SUB-ASSEMBLY

8.

REMOVE VANE PUMP OIL RESERVOIR COVER

9.

DRAIN POWER STEERING FLUID

10. REMOVE FRONT WHEEL RH 11. REMOVE ENGINE UNDER COVER RH 12. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Using SST, disconnect the pressure feed tube from the vane pump. SST 09023-12701 (b) Remove the clip and disconnect the return hose. NOTICE: Take care not to spill fluid on the V belt. (c) Disconnect the oil pressure sensor connector.

SST

C119902E01

13. REMOVE REAR VANE PUMP STAY (a) Remove the bolt, stay and heat insulator. 14. REMOVE VANE PUMP ASSEMBLY (a) Remove bolts B and C, and the adjusting strut. (b) Loosen bolt A sufficiently so that the vane pump can be removed. HINT: Bolt A cannot be removed.

A

C B C119997E01

DISASSEMBLY

SST

PS C119903E01

1.

FIX VANE PUMP ASSEMBLY (a) Using SST, secure the vane pump in a vise. SST 09630-00014 (09631-00132)

2.

REMOVE VANE PUMP OIL RESERVOIR CAP SUBASSEMBLY

3.

REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY (a) Remove the 3 bolts and oil reservoir. (b) Remove the O-ring from the oil reservoir.


POWER STEERING – VANE PUMP

PS–9

4.

REMOVE FRONT PUMP BRACKET (a) Remove the 2 bolts, front bracket and rear bracket.

5.

REMOVE FLOW CONTROL VALVE (a) Remove the pressure port union. (b) Remove the O-ring from the pressure port union. (c) Remove the flow control valve and compression spring.

6.

REMOVE POWER STEERING OIL PRESSURE SENSOR (a) Remove the oil pressure sensor from the front housing.

7.

REMOVE REAR VANE PUMP HOUSING (a) Remove the 4 bolts and rear housing from the front housing. (b) Remove the O-ring from the rear housing.

8.

REMOVE SHAFT SUB-ASSEMBLY WITH PULLEY (a) Using 2 screwdrivers, remove the snap ring from the shaft. (b) Remove the shaft.

9.

REMOVE VANE PUMP ROTOR (a) Remove the 10 vane pump plates. (b) Remove the vane pump rotor.

C119904

C119905

10. REMOVE VANE PUMP CAM RING C119906

11. REMOVE FRONT VANE PUMP SIDE PLATE (a) Remove the side plate from the front housing. (b) Remove the O-ring from the side plate.

C119907

PS


PS–10

POWER STEERING – VANE PUMP

(c) Remove the O-ring from the front housing.

C119908

12. REMOVE VANE PUMP HOUSING OIL SEAL (a) Using a screwdriver and cloth, remove the housing oil seal. NOTICE: Be careful not to damage the housing front.

Cloth

C119909E01

INSPECTION

Bush

1.

INSPECT FRONT VANE PUMP SHAFT AND BUSH IN HOUSING (a) Using a micrometer and caliper gauge, measure the oil clearance. Maximum clearance: 0.07 mm (0.0028 in.) or less If the clearance is greater than the maximum, replace the vane pump.

2.

INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES (a) Using a micrometer, measure the thickness of the vane pump plates. Standard thickness: 1.405 to 1.411 mm (0.05531 to 0.05555 in.)

C119910E02

Thickness

C119911E01

(b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane plates. Maximum clearance: 0.03 mm (0.0012 in.) If the clearance exceeds the maximum, replace the vane pump.

PS Feeler Gauge C119912E01


POWER STEERING – VANE PUMP

3.

PS–11

INSPECT FLOW CONTROL VALVE (a) Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight. If necessary, replace the vane pump.

C119913

(b) Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 to 490 kPa (4 to 5kgf/cm2, 57 to 71 psi) into the opposite side hole, and confirm that air does not come out from the end holes. If necessary, replace the vane pump.

Compressed Air

Close C119914E01

4.

INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using a vernier caliper, measure the free length of the compression spring. Minimum free length: 29.2 mm (1.150 in.) If the length is less than the minimum, replace the vane pump.

5.

INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is severely damaged, it may cause fluid leakage. In that case, replace the vane pump assembly.

Vernier Caliper

C119915E01

SST

REASSEMBLY

Oil Seal

1.

C119916E02

INSTALL VANE PUMP HOUSING OIL SEAL (a) Coat a new housing oil seal lip with power steering fluid. (b) Using SST and a press, press in a new housing oil seal. SST 09950-60010 (09951-00280), 09950-70010 (09951-07100) NOTICE: Make sure that the oil seal is installed correctly.

PS


PS–12

POWER STEERING – VANE PUMP Vinyl Tape

2.

INSTALL SHAFT SUB-ASSEMBLY WITH PULLEY (a) Coat the inside bushing surface of the front housing with power steering fluid. (b) Gradually insert the shaft with pulley. NOTICE: Be careful not to damage the oil seal lip. HINT: Wrap the shaft with vinyl tape before inserting.

3.

INSTALL FRONT VANE PUMP SIDE PLATE (a) Coat a new O-ring with power steering fluid and install it to the front housing.

C119917E01

C119908

(b) Coat a new O-ring with power steering fluid and install it to the front side plate.

C119907

(c) Align the dent of the front side plate with that of the front housing and install them. NOTICE: Make sure that the front side plate is installed correctly.

Front Side Plate

Front Housing

C119919E02

4.

PS

Inscribed Mark

C119920E01

INSTALL VANE PUMP CAM RING (a) Align the dent of the cam ring with that of the front side plate, and install the cam ring with the inscribed mark facing upward.


POWER STEERING – VANE PUMP

5.

PS–13

INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor.

C119921

Round End

(b) Apply power steering fluid to the 10 vane pump plates. (c) Install the vane pump plates with the round end facing outward.

Inward

Outward

C119922E02

6.

INSTALL VANE PUMP SHAFT SNAP RING (a) Using a screwdriver and snap ring expander, install a new snap ring to the shaft.

7.

INSTALL REAR VANE PUMP HOUSING (a) Apply power steering fluid to a new O-ring and install it to the rear housing. (b) Align the straight pin of the rear housing with the dents of the cam ring, the front side plate and the front housing, and install the rear housing with the 4 bolts. Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)

8.

INSPECT PRELOAD (a) Check that the pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: Thread diameter: 10 mm (0.39 in.) Thread pitch: 1.25 mm (0.0492 in.) Bolt length: 50 mm (1.97 in.)

F046045E01

C119923

Service Bolt C119924E01

PS


PS–14

POWER STEERING – VANE PUMP

(c) Using a torque wrench, check the pump rotating torque. Standard rotating torque: 0.27 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less If the rotating torque is not as specified, check installation of the housing oil seal. 9.

INSTALL POWER STEERING OIL PRESSURE SENSOR (a) Apply power steering fluid to a new O-ring and install it to the oil pressure sensor. (b) Install the oil pressure sensor to the front housing. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

10. INSTALL FLOW CONTROL VALVE (a) Apply power steering fluid to the compression spring and flow control valve. (b) Install the compression spring and the flow control valve. (c) Apply power steering fluid to a new O-ring and install it to the pressure port union. (d) Install the pressure port union. Torque: 69 N*m (704 kgf*cm, 51 ft.*lbf) C119904

11. INSTALL FRONT PUMP BRACKET (a) Install the front bracket and rear bracket with the 2 bolts. 12. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY (a) Apply power steering fluid to a new O-ring and install it to the oil reservoir. (b) Install the oil reservoir with the 3 bolts to the front housing. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 13. INSTALL VANE PUMP OIL RESERVOIR CAP SUBASSEMBLY

PS


POWER STEERING – VANE PUMP

PS–15

INSTALLATION NOTICE: When installing, coat the parts indicated by arrows with power steering fluid (see page PS-6). 1.

INSTALL VANE PUMP ASSEMBLY (a) Temporarily install the vane pump with bolt A. HINT: After adjusting the V belt tension, torque the bolt. (b) Install the adjusting strut with bolt B. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) (c) Temporarily install bolt C. HINT: After adjusting the V belt tension, torque the bolt.

2.

INSTALL REAR VANE PUMP STAY (a) Install the rear stay to the rear housing, as shown in the illustration.

A

C B C119997E01

Claw C119925E01

(b) Install the heat insulator and rear stay with the bolt. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) NOTICE: Install the heat insulator by pressing its projection into a hole in the rear bracket, as shown in the illustration.

Rear Bracket Heat Insulator

C119926E02

3. SST

Fulcrum Length

CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Using SST, connect the pressure feed tube. Torque: 41 N*m (414 kgf*cm, 30 ft.*lbf) SST 09023-12701 HINT: • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). • This torque value is effective when SST is parallel to a torque wrench.

C119927E01

PS


PS–16

POWER STEERING – VANE PUMP

(b) Check that the pressure feed tube is properly installed to the rear stay. (c) Connect the return hose with the clip. NOTICE: Take care not to spill fluid on the V belt. (d) Connect the oil pressure sensor connector.

Rear Stay

Pressure Feed Tube Assembly

4.

ADJUST VANE PUMP V BELT (See page EM-7)

5.

INSPECT DRIVE BELT DEFLECTION AND TENSION (See page EM-6)

6.

ADD POWER STEERING FLUID (a) Add power steering fluid (see page SR-2).

7.

BLEED AIR FROM POWER STEERING SYSTEM (a) Bleed air from the power steering system (see page PS-2).

8.

INSPECT POWER STEERING FLUID LEAK

9.

INSTALL ENGINE UNDER COVER RH

C119996E02

10. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 11. CHECK POWER STEERING FLUID LEVEL IN RESERVOIR (See page PS-3) 12. INSTALL VANE PUMP OIL RESERVOIR COVER 13. INSTALL COWL PANEL SUB-ASSEMBLY 14. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See page WW-10) 15. INSTALL COWL TOP VENTILATOR LOUVER LH (See page WW-10) 16. INSTALL COWL TOP VENTILATOR LOUVER RH (See page WW-10) 17. INSTALL HOOD TO COWL TOP SEAL (See page WW10) 18. INSTALL FRONT WIPER ARM LH (See page WW-11) 19. INSTALL FRONT WIPER ARM RH (See page WW-11)

PS


PS–20

POWER STEERING – POWER STEERING LINK

REMOVAL 1.

REMOVE FRONT WIPER ARM RH (See page WW-7)

2.

REMOVE FRONT WIPER ARM LH (See page WW-7)

3.

REMOVE HOOD TO COWL TOP SEAL (See page WW-7)

4.

REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-7)

5.

REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-7)

6.

REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-8)

7.

REMOVE COWL PANEL SUB-ASSEMBLY

8.

INSPECT FRONT WHEELS FACING STRAIGHT AHEAD

9.

REMOVE STEERING COLUMN HOLE COVER PLATE (See page SR-8)

10. REMOVE STEERING SLIDING YOKE SUBASSEMBLY (a) Fix the steering wheel with the seat belt in order to prevent rotation. HINT: This operation is also useful to prevent damaging the spiral cable.

C119931

(b) Put matchmarks on the sliding yoke and intermediate shaft. (c) Loosen the bolt, and then disconnect the sliding yoke from the intermediate shaft. Matchmark

C119932E01

B

11. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Detach clip A and disconnect the hole cover. NOTICE: Be careful not to damage clip B.

A

12. REMOVE HOOD SUB-ASSEMBLY

PS

13. DRAIN POWER STEERING FLUID 14. REMOVE FRONT WHEELS C119933E01

15. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (See page DS-5)


POWER STEERING – POWER STEERING LINK

PS–21

16. DISCONNECT TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedures described for the LH side. 17. REMOVE ENGINE UNDER COVER LH 18. REMOVE ENGINE UNDER COVER RH Clip

19. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Remove the clip and disconnect the return hose. (b) Using SST, disconnect the pressure feed tube. SST 09023-12701 (c) Using SST, remove the return tube. SST 09023-12701

Return Hose

SST Pressure Feed Tube C119934E01

(d) Remove the bolt and disconnect the tube clamp. 20. DISCONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See page DS-5) 21. DISCONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH HINT: Use the same procedures described for the LH side. C119935

No. 1 Engine Hanger

C119936E01

22. SUSPEND ENGINE ASSEMBLY (a) Install the 2 No. 1 engine hangers with the bolts in the correct direction. Parts No.: No. 1 engine hanger: 12281-21010 Bolt: 91642-81025 Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) (b) Hold the engine with the sling device and chain hoist. NOTICE: Do not hang the engine by hooking the chain to any other parts. 23. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (a) Remove the 4 bolts and 2 reinforcements.

PS C119937


PS–22

POWER STEERING – POWER STEERING LINK

(b) Remove the bolt and 2 nuts, and disconnect the engine mounting insulator rear. (c) Using a transmission jack, support the crossmember.

C119938

(d) Remove the 4 bolts and crossmember. 24. REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR (a) Remove the 2 bolts and heat insulator. 25. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

C119939

26. REMOVE STEERING INTERMEDIATE SHAFT (a) Put matchmarks on the steering link and intermediate shaft. (b) Remove the bolt and intermediate shaft.

Matchmark

C119940E01

27. REMOVE POWER STEERING LINK ASSEMBLY (a) Put matchmarks on the steering link and No. 2 bracket.

Matchmark

C119941E01

(b) Remove the 4 bolts, nuts, No. 2 bracket, No. 2 grommet and steering link. NOTICE: • Torque the bolt with the nut fixed as the nut has its own stopper. • Do not turn the nut.

PS C119942


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POWER STEERING – POWER STEERING LINK

PS–23

28. REMOVE STEERING TURN PRESSURE TUBE RH (a) Using SST, remove the turn pressure tube. SST 09023-38201 (b) Remove the 2 O-rings from the right turn pressure tube.

O-Ring

SST

29. REMOVE STEERING TURN PRESSURE TUBE LH HINT: Use the same procedures described for the RH side. C119943E02

DISASSEMBLY

SST

1.

FIX POWER STEERING LINK ASSEMBLY (a) Using SST, secure the steering link. SST 09612-00012 HINT: Wrap the SST with vinyl tape before use.

2.

REMOVE TIE ROD END SUB-ASSEMBLY LH (a) Put matchmarks on the tie rod end LH and rack end. (b) Loosen the lock nut and remove the tie rod end and lock nut.

3.

REMOVE TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedures described for the LH side.

4.

REMOVE STEERING RACK BOOT CLIP (a) Remove the 2 boot clips.

5.

REMOVE NO. 2 STEERING RACK BOOT CLAMP (a) Using a screwdriver, remove the rack boot clamp. NOTICE: Be careful not to damage the boot.

6.

REMOVE NO. 1 STEERING RACK BOOT CLAMP HINT: Use the same procedures described for the No. 2 side.

7.

REMOVE NO. 2 STEERING RACK BOOT

8.

REMOVE NO. 1 STEERING RACK BOOT

C119944E01

Matchmark

C119945E01

C119946

PS


PS–24

POWER STEERING – POWER STEERING LINK

9. LH SST Hold

REMOVE STEERING RACK END SUB-ASSEMBLY (a) Using SST, remove the 2 rack ends. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

Turn SST RH SST Turn Hold SST

C119947E01

10. REMOVE RACK GUIDE (a) Using SST, remove the spring cap lock nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

SST

C119948E01

(b) Using a 19 mm hexagon wrench, remove the rack guide spring cap. (c) Remove the rack guide spring, rack guide spring spacer and rack guide.

Hexagon Wrench

C119949E01

Matchmark

PS C119950E01

11. REMOVE POWER STEERING CONTROL VALVE (a) Put matchmarks on the control valve and rack housing. (b) Remove the 2 bolts and control valve. (c) Remove the gasket. 12. REMOVE CYLINDER END STOPPER (a) Using needle nose pliers, remove the hole snap ring. (b) Pull out the cylinder end stopper.

Profile for 1631438

2006 SCION XA Service Repair Manual  

2006 SCION XA Service Repair Manual  

Profile for 1631438
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